Gaming chip and method of manufacturing

ABSTRACT

Gaming chips, for example, poker chips, comprise an inner metal coin provided with at least one aperture therethrough, and a plastic casing including a first plastic casing portion extending around a perimeter of the inner metal coin and a second plastic casing portion extending through the aperture and over opposite faces of the inner metal coin. The gaming chips may be manufactured using injection molding techniques.

RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119 of U.S. Application Ser. No. 60/616,555 filed Oct. 6, 2004.

FIELD OF THE INVENTION

The present invention is directed to a gaming chip, and, more particularly, to a gaming chip having an improved look and feel. The invention is also directed to methods of manufacturing a gaming chip.

BACKGROUND OF THE INVENTION

Gaming chips or tokens are well known for use in card games and the like. Many times, such gaming chips are formed entirely of plastic, for example by injection molding, and are therefore easily mass produced. Other gaming chips have been formed entirely of metal and these chips are typically of a higher weight and provide a more substantive feel. However, metal chips are significantly more expensive to produce as compared with injection molded plastic chips. The metal chips can also be advantageous for use in applications where detection of the presence of the metal chip by, for example, conductivity measurements, are desired.

Composite gaming chips, formed of both metal and plastic materials, are also known. For example, the Jones U.S. Pat. Nos. 3,968,582 and 4,827,640 disclose gaming tokens which may be formed of both metal and plastic components in combination. The Boiron U.S. Pat. No. 6,021,949, the Shumi et al U.S. Pat. Nos. 6,372,320 and 6,488,210 and the Zurawski et al U.S. Pat. No. 6,514,374 disclose additional gaming tokens or chips which may be formed of a plurality of materials and components. However, gaming chips or tokens which are formed of a plurality of components are often of a construction which does not facilitate mass production. Accordingly, further improvements in gaming chips are desired.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide novel gaming chips which have a good substantive feel. It is an additional object of the invention to provide gaming chips and methods for manufacturing gaming chips which are amenable to mass production.

In one embodiment, the invention is directed to a gaming chip which comprises an inner metal coin provided with at least one aperture therethrough, and a plastic casing. The plastic casing includes a first plastic casing portion extending around a perimeter of the inner metal coin and a second plastic casing portion extending through the aperture and over opposite faces of the inner metal coin.

In a further embodiment, the invention is directed to a method of manufacturing a gaming chip. The method comprises providing a metal coin having at least one aperture extending therethrough, injection molding a first plastic casing portion around a perimeter of the metal coin, and injection molding a second plastic casing portion over opposite faces of the metal coin. The second plastic casing portion extends through the aperture in the metal coin.

The gaming chips according to the present invention are advantageous in comprising plastic material while exhibiting a good substantive feel. Additionally, the gaming chips may be manufactured accordingly to a method which facilitates mass production. These and additional objects and advantages will be more fully apparent in view of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description will be more fully understood in view of the drawing in which:

FIG. 1 is a top view of a first embodiment of a gaming chip according to the invention;

FIG. 2 is a cross sectional view taken along line 2-2 in FIG. 1;

FIG. 3 is a top view of a metal coin suitable for use in the gaming chip of the invention;

FIG. 4 is an enlarged view of portion A of FIG. 2;

FIG. 5 is a top view of a second embodiment of a gaming chip according to the invention; and

FIG. 6 is a cross sectional view of a mold in which a metal coin has been inserted for manufacture of a gaming chip according to the present invention.

DETAILED DESCRIPTION

The gaming chips according to the present invention are formed from a combination of plastic and metal materials. More particularly, with reference to the drawings, FIGS. 1 and 2 set forth top and cross sectional views of a first embodiment of a gaming chip 10 according to the invention. The gaming chip 10 includes an inner metal coin 12 and a plastic casing 14. The metal coin 12 is generally of a planar disk shape having opposite surfaces. The plastic casing 14 includes a first plastic casing portion 16 which extends around a perimeter 15 of the inner metal coin 12. The first plastic casing portion therefore has a generally annular configuration. The casing 14 further includes a second plastic casing portion 18 which extends through an aperture 22 provided in the coin 12 and over opposite surfaces 26 and 28 of the coin 12. The gaming chip 10 is of a substantially circular shape as shown in FIG. 1, and in a specific embodiment, the metal coin 12 has a similar circular shape with a smaller diameter than the gaming chip. In one embodiment, the diameter of the metal coin 12 is at least about 10%, more specifically at least about 15%, smaller than the diameter of the gaming chip.

FIG. 3 shows a top view of the metal coin 12 included in the gaming chip of the invention. The metal coin may be formed of any suitable metal, for example aluminum, steel or the like, and in one embodiment has a substantially circular form. The metal coin is provided with the at least one aperture 22 which extends through the coin. While the coin shown in FIG. 3 includes a single aperture 22, it is equally within the scope of the invention to include two or more apertures within the metal coin 12.

The plastic casing 14, comprising the first plastic casing portion 16 and the second plastic casing portion 18, retains the metal coin in the gaming chip. In one embodiment, the plastic casing 14 completely encases the inner metal coin within the plastic casing, so that no portion of the metal coin is exposed. It should be recognized however that it is equally within the scope of the inventive gaming chip that one or more portions of the metal coin may be exposed, for example where the second plastic casing portion does not extend completely over opposite faces of the inner metal coin to meet the first plastic casing.

As shown in the embodiment of FIGS. 1 and 2, the first plastic casing portion 14, which extends around the perimeter 15 of the inner metal coin, may also extend over a perimeter area 24 on each of the opposite surfaces 26 and 28 of the inner metal coin 12. The perimeter area 24 on the top surface 26 of the coin 12 in FIG. 3 is shown as generally defined by a phantom line. However, one skilled in the art will appreciate that the radial length of the perimeter area 24 may be increased or decreased as desired. The first plastic casing portion extension over the perimeter area of the surfaces of the inner metal coin is indicated generally at 30 in FIG. 2.

In the embodiment of the gaming chip set forth in FIGS. 1 and 2, the extension 30 is preferably substantially coplanar with the adjacent surfaces of the second plastic casing portion 18, whereby any variations in the thickness of the chip in the area of the first plastic casing portion and the second plastic casing portion are less than several mils. In one embodiment, there is a slight variation in the thickness of the respective casing portions. For example, as shown in FIG. 4, which is an enlargement of area A of FIG. 2, the extension 30 is shown as presenting a raised edge 32 on each opposite face of the chip relative to the second plastic casing portion 18. The raised edge 32 may extend beyond the adjacent surface of the second portion casing 18 a height of, for example, one to several mils, if desired. The edge may contribute to an improved handling of the gaming chip by a user, counter or sorter, or may facilitate placement of a decorative sticker on the surface of the gaming chip, as will be discussed in further detail hereafter.

The first and second plastic casing portions may be formed of any suitable plastic materials, as desired, including, but not limited to, polyolefins, such as polyethylene and/or polypropylene, polyacrylate, polymethacrylate, polycarbonate, polyurethane, or the like. The respective casing portions may be formed of the same plastic composition or alternatively, the respective casing portions may be formed of different plastic compositions, i.e., compositions which differ in types or amounts of components therein. The casing portions may be formed with the same surface texture, or alternatively, may be provided with differing surface textures. In one specific embodiment, the first plastic casing portion and the second plastic casing portion are formed of different plastic compositions and are provided with different surface textures.

Moreover, the respective plastic casing portions may be formed of the same colored material, or of different colored material, as desired. Further, each casing portion may be formed of a single color of plastic, or may comprises subportions of differeing colors. Additionally, any portion of the plastic casing may be provided with ink printing or other decorative indicia. In a second embodiment of a gaming chip according to the invention shown in FIG. 5, a chip 40 includes a plastic casing comprising a first plastic casing portion 42 and a second plastic casing portion 43. At least the first plastic casing portion 42 is provided with multicolored decorative design. The decorative design is shown generally at 44 can therefore contribute to the appeal of the gaming chip.

In an optional embodiment, the gaming chip includes at least one decorative sticker adhesively adhered on at least one surface of the second plastic casing portion. For example, in the embodiment shown in FIG. 5, the gaming chip 40 includes a sticker 46 adhesively adhered to the top surface of the second plastic casing portion 43. In a further embodiment, a decorative sticker is provided on each of the opposite surfaces of the second plastic casing portion.

The gaming chip as described herein may be manufactured according to any suitable method. However, in a specific embodiment, the first plastic casing portion is injection molded onto the perimeter of the inner metal coin. In a further embodiment, the second casing portion is injection molded onto opposite surfaces of the inner metal coin, with the second casing portion extending through the aperture in the metal coin. In a specific embodiment, the first plastic casing portion and the second plastic casing portion are injection molded in separate steps.

The aperture provided in the metal coin facilitates mass production of the gaming chip according to the present invention using injection molding techniques. That is, in a first injection molding step wherein the first plastic casing portion is injection molded around a perimeter of the metal coin, the metal coin is positioned for injection molding by inserting a pin through the aperture. A cross sectional view of a mold suitable for use in such a method is shown in FIG. 6. The mold 50 includes a lower mold half 52 which is provided with a pin 54 and an annular cavity 56. The mold 50 further includes an upper mold half 58 provided with an annular cavity 60. As shown in FIG. 6, the lower mold half 52 receives the metal coin 12 with the pin 54 of the mold inserted within the aperture 22 in order to position and maintain the coin in an appropriate position for receiving the injection molding of the first plastic casing portion. Thus, plastic material is injection molded into the cavity area formed by cavities 56 and 60, resulting in injection molding formation of the first plastic casing portion around the perimeter of the metal coin. Upon completion of this injection molding step, the coin may be inserted in a second mold where it is positioned and maintained using the first plastic casing portion and thereby exposing the opposite surfaces of the metal coin and the aperture for receipt of a second plastic material for formation of the second plastic casing portion over opposite faces of the metal coin and extending through the aperture. Accordingly, the aperture in the metal coin facilitates manufacture of the present gaming chips in mass quantities using injection molding techniques. One skilled in the art will appreciate that other plastic molding techniques may be used in preparing gaming chips according to the invention and the resulting gaming chips are equally within the scope of the present invention.

The size of the metal coin employed in the gaming chip, including the thickness and diameter, may be varied in order to increase or decrease the weight and substantive feel of the chip. In one embodiment, the metal coin is sized and the coin and casing materials are selected as to provide a chip having a weight of from about 5 to 15 grams, more specifically from about 8 to 13 grams, more particularly of about 11 or 11.5 grams.

The examples and specific and preferred embodiments set forth herein are exemplary in nature only and are not intended to be limiting of the gaming chips and methods defined by the following claims. Additional examples and embodiments of the invention will be apparent to those of ordinary skill in the art and are encompassed by the following claims. 

1. A gaming chip, comprising (a) an inner metal coin provided with at least one aperture therethrough, and (b) a plastic casing including a first plastic casing portion extending around a perimeter of the inner metal coin and a second plastic casing portion extending through the aperture and over opposite faces of the inner metal coin.
 2. The gaming chip of claim 1, wherein the first plastic casing portion is injection molded on the perimeter of the inner metal coin.
 3. The gaming chip of claim 2, wherein the first plastic casing portion extends over a perimeter area of each opposite face of the inner metal coin.
 4. The gaming chip of claim 3, wherein the first plastic casing portion presents a raised edge on each opposite face relative to the second plastic casing portion.
 5. The gaming chip of claim 1, wherein the plastic casing completely encases the inner metal coin.
 6. The gaming chip of claim 1, wherein the first plastic casing portion and the second plastic casing portion are formed of different plastic compositions.
 7. The gaming chip of claim 6, wherein the first plastic casing portion and the second plastic casing portion are injection molded onto the coin.
 8. The gaming chip of claim 1, wherein the first plastic casing portion is multicolored.
 9. The gaming chip of claim 1, further comprising a decorative sticker on at least one surface of the second plastic casing portion.
 10. The gaming chip of claim 9, comprising a decorative sticker on each surface of the second plastic casing portion.
 11. A method of manufacturing a gaming chip, comprising (a) providing a metal coin having at least one aperture extending therethrough, (b) injection molding a first plastic casing portion around a perimeter of the metal coin, and (c) injection molding a second plastic casing portion over opposite faces of the metal coin, the second plastic casing portion extending through the aperture.
 12. The method of claim 11, wherein the metal coin is positioned for injection molding of the first plastic casing portion by inserting a pin through the aperture.
 13. The method of claim 12, wherein the pin is removed prior to injection molding of the second plastic casing portion.
 14. The method of claim 11, wherein the first plastic casing portion extends over a perimeter area of each opposite face of the inner metal coin.
 15. The method of claim 11, wherein the first plastic casing portion presents a raised edge on each opposite face relative to the second plastic casing portion.
 16. The method of claim 11, wherein the plastic casing completely encases the inner metal coin.
 17. The method of claim 11, comprising adhesively securing a decorative sticker to at least one surface of the second plastic casing portion.
 18. The method of claim 17, comprising adhesively securing a decorative sticker on each surface of the second plastic casing portion. 